Emberbed assembly for use in electric fireplace

ABSTRACT

An electric fireplace that is configured to look more realistic, i.e. more like a traditional wood-burning fireplace, includes a grate and an emberbed. The grate has a substantially horizontally-oriented middle section. The emberbed is positioned substantially directly below the middle section of the grate. Additionally, the emberbed is positioned spaced apart from the grate by a bed gap. The bed gap can be between approximately one-half inch and four inches. Additionally, the emberbed can be selectively coupled to the grate.

RELATED APPLICATION

The application claims priority on U.S. Provisional Application Ser. No.62/513,166 filed on May 31, 2017, entitled “EMBERBED ASSEMBLY FOR USE INELECTRIC FIREPLACE”. As far as is permitted, the contents of U.S.Provisional Application Ser. No. 62/513,166 are incorporated in theirentirety herein by reference.

BACKGROUND

Fireplaces of various types can be installed in homes and commercialestablishments as a means to provide a source of heat and for aestheticreasons. Although traditionally such fireplaces have most often takenthe form of wood-burning fireplaces and gas-burning fireplaces, electricfireplaces have become increasingly popular in recent years. An electricfireplace is typically designed to look like a traditional wood-burningfireplace, but does not actually burn wood. As such, there is acontinuing desire to make electric fireplaces look more realistic, i.e.to make electric fireplaces look more like a traditional wood-burningfireplace.

SUMMARY

The present invention is directed toward an electric fireplace that isconfigured to look more realistic, i.e. more like a traditionalwood-burning fireplace. In various embodiments, the electric fireplaceincludes a grate and an emberbed. The grate has a substantiallyhorizontally-oriented middle section. The emberbed is positionedsubstantially directly below the middle section of the grate.Additionally, the emberbed is positioned spaced apart from the grate bya bed gap.

In some embodiments, the bed gap is between approximately one-half inchand four inches. Additionally, the emberbed can be selectively coupledto the grate.

The electric fireplace can also include an assembly base that is formedtogether with the emberbed as a unitary structure. The unitary structureof the emberbed and the assembly base can then be selectively coupled tothe grate. In some such embodiments, the assembly base provides a flatsurface that extends laterally (e.g., to the left and to the right) awayfrom the emberbed.

In certain embodiments, the electric fireplace can further include anassembly light source that is positioned directly underneath theemberbed. The assembly light source can be selectively activated tocreate a glowing effect for the emberbed. In some such embodiments, theassembly light source includes a plurality of LED light bulbs.

The components of the electric fireplace can be formed from any suitablematerials. For example, in some non-exclusive alternative embodiments,the emberbed can be formed from at least one of vacuum-molded plastic,pour-molded resin, injected plastic or paper pulp. Additionally, incertain non-exclusive embodiments, the grate can be formed from metallicmaterials. Alternatively, the emberbed and/or the grate can be formedfrom other suitable materials. For example, in other embodiments, thegrate can be formed from plastic, resin, and/or another suitablematerial.

Additionally, in some embodiments, the electric fireplace can furtherinclude at least one simulated log that is positioned on top of thegrate. The at least one simulated log can be formed from a molded resinmaterial. Alternatively, one or more of the logs can be made of othermaterials, including, but not limited to, vacuum molded plastic,pour-molded resin, injected plastic or paper pulp.

The electric fireplace can further include a fireplace housing, whereinthe grate and the emberbed are positioned substantially within thefireplace housing.

In another embodiment, the present invention is further directed towarda grate and an emberbed assembly that is selectively coupled to thegrate.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of this invention, as well as the invention itself,both as to its structure and its operation, will be best understood fromthe accompanying drawings, taken in conjunction with the accompanyingdescription, in which similar reference characters refer to similarparts, and in which:

FIG. 1 is a front perspective view of an embodiment of an electricfireplace having features of the present invention;

FIG. 2A is a front perspective view of a portion of another embodimentof the electric fireplace;

FIG. 2B is a partial cutaway view of the portion of the electricfireplace taken on line B-B in FIG. 2A; and

FIG. 2C is an exploded partial cutaway view of the portion of theelectric fireplace illustrated in FIG. 2B.

DESCRIPTION

Embodiments of the present invention are described herein in the contextof an emberbed assembly for use in an electric fireplace. Morespecifically, as provided herein, the emberbed assembly is configured togive the electric fireplace a more realistic looking appearance, i.e.more like a traditional wood-burning fireplace, in comparison toconventional electric fireplaces.

Those of ordinary skill in the art will realize that the followingdetailed description of the present invention is illustrative only andis not intended to be in any way limiting. Other embodiments of thepresent invention will readily suggest themselves to such skilledpersons having the benefit of this disclosure. Reference will now bemade in detail to implementations of the present invention asillustrated in the accompanying drawings.

In the interest of clarity, not all of the routine features of theimplementations described herein are shown and described. It will, ofcourse, be appreciated that in the development of any such actualimplementation, numerous implementation-specific decisions must be madein order to achieve the developer's specific goals, such as compliancewith application-related and business-related constraints, and thatthese specific goals will vary from one implementation to another andfrom one developer to another. Moreover, it will be appreciated thatsuch a development effort might be complex and time-consuming, but wouldnevertheless be a routine undertaking of engineering for those ofordinary skill in the art having the benefit of this disclosure.

FIG. 1 is a front perspective view of an embodiment of an electricfireplace 10 having features of the present invention. As illustratedherein, the electric fireplace 10 can be used to provide heat and tosimulate a wood-burning fire, e.g., in a room of a home or other type ofbuilding. More particularly, in certain embodiments, the electricfireplace 10 can be configured to look like a traditional wood-burningfireplace, although the electric fireplace 10 does not actually burnwood.

The design of the electric fireplace 10 can be varied. In certainembodiments, as illustrated in FIG. 1, the electric fireplace 10 caninclude a fireplace housing 12, a viewing area 14 within the fireplacehousing 12, a simulated flame 16 (i.e. when the electric fireplace 14 isin use), one or more simulated logs 18, a first light source 20(illustrated in phantom) that can be used to selectively generate thesimulated flame 16 and create a glowing effect for the simulated logs20, a grate 22, a heater 24, a controller 26, and an emberbed assembly28. Alternatively, the electric fireplace 10 can include more componentsor fewer components than those specifically illustrated in FIG. 1. Forexample, in one non-exclusive alternative embodiment, the electricfireplace 10 can be designed without the heater 24.

As an overview, in certain embodiments, the electric fireplace 10 isuniquely configured to provide a more realistic appearance for theelectric fireplace 10, i.e. more like a traditional wood-burningfireplace. More particularly, the emberbed assembly 28, as illustratedand described herein, is configured to look more realistic as it has asmaller and lower profile than in existing electric fireplaces and ispositioned substantially directly below at least a portion of the grate22 and is spaced apart a bed gap 30 from the main substantiallyhorizontally-oriented middle section 22B of the grate 22. Additionally,in various embodiments, the emberbed assembly 28 includes an emberbed 32and an assembly base 34 that are formed together as a unitary structure,and an assembly light source 236 (illustrated in FIG. 2B) that can beused to create a glowing effect for the emberbed 32.

The fireplace housing 12 can be sized and shaped to retain most, if notall, of the remaining components of the electric fireplace 10. Inparticular, in many embodiments, the simulated flame 16 (i.e. when theelectric fireplace 10 is in use), the one or more simulated logs 18, thefirst light source 20, the grate 22, the heater 24, the controller 26and the emberbed assembly 28 can be positioned substantially within thefireplace housing 12. In some embodiments, the fireplace housing 12 hasa substantially rectangular shape, and includes a housing base 38 thatsupports various components of the electric fireplace 10. Additionally,the fireplace housing 12 can further include a window (not shown)located at a front side of the fireplace housing 12. The window caninclude tempered glass or a meshed door through which the simulatedflame 16 can be seen. Alternatively, the fireplace housing 12 can have adifferent shape and/or the fireplace housing 12 can be designed withoutthe window.

Further, the fireplace housing 12 can be formed from any suitablematerials. For example, in various embodiments, the fireplace housing 12can be formed from any of a number of suitable metallic materials.

The viewing area 14 is the area within the fireplace housing 12 in whichthe simulated flame 16, the simulated logs 18, the grate 22 and theemberbed assembly 28 are displayed and can be seen by the user.

The simulated flame 16 can be formed from any suitable method. Forexample, in various embodiments, the electric fireplace 10 can utilizethe first light source 20 to illuminate a reflective medium (not shown),e.g., a suitable metal material, to generate the simulated flame 16,i.e. a flickering flame image. The first light source 20 can have anysuitable design. For example, in one non-exclusive alternativeembodiment, the first light source 20 can include an LED panel havingone or more LED light bulbs. Alternatively, the first light source 20can include other types of light bulbs or another type of light source.As noted and as shown in FIG. 1, in various embodiments, the simulatedflame 16, when in use, is displayed within the viewing area 14 of theelectric fireplace 10.

Additionally and as noted above, the simulated (or artificial) logs 18can also be positioned within the viewing area 14. Similar to thesimulated flame 16, the simulated logs 18 can utilize the first lightsource 20 to create a glowing effect for the simulated logs 20. Thus,the combination of the simulated logs 18 and the simulated flame 16 canuse the first light source 20 to create the appearance of burning logs,thereby closely simulating the flames of a wood-burning fireplace.Alternatively, the electric fireplace 10 can include a second lightsource (not shown) to create the glowing effect for the simulated logs.

Further, as illustrated, the simulated logs 18 can be placed on top ofthe grate 22, i.e. an actual or a simulated grate.

As illustrated, the grate 22 includes a pair of substantiallyvertically-oriented, spaced apart ends 22A, and a substantiallyhorizontally-oriented middle section 22B that extends between the ends22A. Additionally, as noted, the grate 22 is configured to support thesimulated logs 18 above the housing base 38 and/or the emberbed assembly28. More particularly, in various embodiments, the simulated logs 18 aresupported by the substantially horizontally-oriented middle section 22Bof the grate 22.

As described herein, and as illustrated in FIG. 1, the middle section22B of the grate 22 provides a base supporting structure for thesimulated logs 18 that is oriented substantially horizontally. Thus,even in embodiments where the middle section 22B of the grate 22includes portions that slope generally upwardly, downwardly and/or at anangle away from the substantially horizontal base supporting structureof the middle section 22B, the middle section 22B can still be said tobe substantially horizontally oriented.

Further, the heater 24, e.g., an integrated electric heater, can beconfigured to provide heated air which can be directed in a generallyoutward direction away from the electric fireplace 10. Moreparticularly, in certain embodiments, the heater 24 can include a blower(not shown) that blows hot air through heat vents 40 into the areasurrounding the electric fireplace 10, e.g., a room in a house, in orderto heat such area. In some such embodiments, the heat vents 40 can bepositioned at or near an upper portion of the fireplace housing 12.

The controller 26 can include one or more circuits or processors thatcan be utilized to control the various functions of the electricfireplace 10. For example, the controller 26 can be utilized to activateand/or control (i) the intensity of the first light source 20 within theelectric fireplace 10 that generates the simulated flame 16 and createsthe glowing effect for the simulated logs 18, (ii) the speed of theblower within the heater 24 to regulate the amount of heat produced anddispersed by the heater 24, and (iii) the intensity of the assemblylight source 236 that creates the glowing effect for the emberbed 32.

The emberbed assembly 28, e.g., formed at least in part by the emberbed32 and/or the assembly base 34, is positioned adjacent to the housingbase 38 and substantially below the grate 22, e.g., substantiallydirectly below the middle section 22B of the grate 22. However, asutilized herein, the emberbed assembly 28 being positioned substantiallydirectly below the grate 22 allows for some of the emberbed 32 and/orthe assembly base 34 to extend outwardly enough that they are notpositioned directly below the grate 22. Additionally, as providedherein, in certain embodiments, the emberbed assembly 28 is configuredto be selectively coupled to the grate 22. In existing electricfireplaces, the emberbed is typically formed together with the grate asa unitary structure. However, in the present invention, the emberbed 32(and the assembly base 34) is formed separate from the grate 22, and, asnoted, can be selectively coupled to the grate 22. With such design, theemberbed 32 can have a smaller and lower profile that enables the bedgap 30, and thus provides a more realistic appearance for the emberbed32, and thus for the electric fireplace 10.

Further, as noted above, the emberbed 32 is spaced apart the bed gap 30from the substantially horizontally-oriented middle section 22B of thegrate 22 (i.e. ignoring the ends 22A of the grate 22 that curve downwardand provide support for the rest of the grate 22). It should beappreciated that due to the various bumps, curves and undulations formedin the emberbed 32 that the size of the bed gap 30 will vary across thesurface of the emberbed 32. Thus, as utilized herein, the bed gap 30 canbe defined as the minimum distance between an upper surface 32A of theemberbed 32 and the substantially horizontally-oriented middle sectionof the grate 22, i.e. as measured in a generally vertical direction.

As provided herein, the size of the bed gap 30 can be varied. Forexample, in certain non-exclusive alternative embodiments, the size ofthe bed gap 30 can be between approximately one-half inch and fourinches. Alternatively, in other embodiments, the size of the bed gap 30can be greater than four inches or less than one-half inch. As other,non-exclusive examples, the bed gap 30 can be between approximatelyone-quarter inch and six inches. Stated is a different fashion, inalternative non-exclusive embodiments, the bed gap 30 can be at leastone-eight (⅛), one-quarter (¼), one-half (½), three-quarters (¾), one,two, three, four, five, or six inches.

Still alternatively, in one embodiment, the electric fireplace 10 can bedesigned without an actual bed gap, but with a mere illusion of a bedgap between the emberbed 32 and the middle section 22B of the grate 22.

FIG. 2A is a front perspective view of a portion of another embodimentof the electric fireplace 210. As shown, the electric fireplaceillustrated in FIG. 2A is substantially similar to the electricfireplace 10 illustrated and described above in relation to FIG. 1,e.g., with only the simulated logs 218 having a slightly differentappearance than what is shown in FIG. 1. In particular, FIG. 2A againprovides a perspective view of the simulated logs 218, the grate 222 andthe emberbed assembly 228 of the electric fireplace 210.

FIG. 2A further illustrates a slightly different perspective of the bedgap 230 that is formed between the upper surface 232A of the emberbed232 and the main substantially horizontally-oriented middle section 222Bof the grate 222.

FIG. 2B is a partial cutaway view of the portion of the electricfireplace 10 taken on line B-B in FIG. 2A. As shown, FIG. 2B againillustrates the simulated logs 218, the grate 222 and the emberbedassembly 228, i.e. the emberbed 232 and the assembly base 234.Additionally, FIG. 2B also illustrates the assembly light source 236that can be utilized, i.e. selectively activated, for purposes ofcreating a glowing effect for the emberbed 232. FIG. 2B also illustratesanother view of the bed gap 230 between the emberbed 232 and the middlesection 222B of the grate 222.

The simulated logs 218 can be formed from any suitable materials. Forexample, in certain non-exclusive alternative embodiments, the simulatedlogs 218 can be hollow molded logs that are formed from a molded resinmaterial. Alternatively, the simulated logs 218 can be formed fromanother suitable material.

Additionally, the grate 222 can also be formed from any suitablematerials. For example, in certain non-exclusive alternativeembodiments, the grate 222 can be formed from metallic materials such asa welded steel or aluminum material. Alternatively, the grate 222 can beformed from plastic, resin, and/or another suitable material.

Further, the emberbed assembly 228, i.e. the emberbed 232 and theassembly base 234, can also be formed from any suitable materials. Forexample, in some embodiments, the emberbed assembly 228 can be formedfrom vacuum-molded plastic, pour-molded resin, injected plastic or paperpulp. Alternatively, the emberbed assembly 228 can be formed from othersuitable materials.

Still further, in alternative embodiments, the emberbed 232 can beformed separately from the grate 222, or the emberbed 232 can beintegrally formed with the grate 222 as a unitary structure.

Additionally, the assembly light source 236 can have any suitabledesign. For example, as illustrated, the assembly light source 236 caninclude a flat, PCB board 236A upon which are mounted a plurality of LEDlight bulbs 236B. Additionally, as shown, the assembly light source 236can be positioned substantially below, e.g., substantially directlybelow, the emberbed 232. With such design, the assembly light source 236can have a low profile that can fit easily underneath the emberbed 232in order to create the glowing effect for the emberbed 232.Alternatively, the assembly light source 236 can have another suitabledesign and/or use a different type of light bulbs. Still alternatively,the assembly light source 236 can be positioned in another mannerrelative to the emberbed 232, i.e. not substantially directly below theemberbed 232.

The location and size of the PCB board 236A can be varied. For example,in some embodiments, the PCB board 236A can be substantiallyrectangle-shaped, with an upper surface 236C upon which the plurality ofLED light bulbs 236B are secured or mounted. Alternatively, the PCBboard 236A can have another suitable shape.

Additionally, the quantity, size, type and placement of the LED lightbulbs 236B can also be varied. For example, in some embodiments, theassembly light source 236 can include twenty LED light bulbs 236B.Alternatively, the assembly light source 236 can include greater thantwenty or fewer than twenty LED light bulbs 236B.

It should be appreciated that the low profile for the assembly lightsource 236 enables the emberbed assembly 228 as a whole to have asmaller and lower profile such that it can fit substantially below thegrate 222 and be spaced apart from the grate 222, i.e. the middlesection 222B of the grate 222, by the bed gap 230. As noted, the lowprofile for the emberbed assembly 228, i.e. the emberbed 232, enablesthe electric fireplace 210 to have a more realistic appearance.

It should further be appreciated that the use of LED light bulbs 236Bmake it generally unnecessary to access the assembly light source 236 asthe LED light bulbs have a very long life span and do not need to beregularly replaced.

FIG. 2C is an exploded partial cutaway view of the portion of theelectric fireplace 210 illustrated in FIG. 2A. In particular, FIG. 2Cagain illustrates the simulated logs 218, the grate 222 and the emberbedassembly 228, i.e. the emberbed 232, the assembly base 234 and theassembly light source 236. Additionally, FIG. 2C also illustrates thatthe electric fireplace 210 can further include at least one firstfastener 242 (two are illustrated in FIG. 2C) that can be utilized tofasten the simulated logs 218 to the grate 222; and at least one secondfastener 244 (two are illustrated in FIG. 2C) that can be utilized tofasten the grate 222 to the emberbed assembly 228, i.e. to the emberbed232 and/or the assembly base 234.

The first fasteners 242 can have any suitable design. For example, asshown in the embodiment illustrated in FIG. 2C, the first fasteners 242can be screws that extend through the grate 222 and into and/or throughat least a portion of the simulated logs 218. Alternatively, the firstfasteners 242 can have another suitable design. Still alternatively, thesimulated logs 218 can be selectively coupled to the grate 222 inanother suitable manner.

Somewhat similarly, the second fasteners 244 can have any suitabledesign. For example, in the embodiment shown in FIG. 2C, the secondfasteners 244 can be screws that extend through the emberbed assembly228, i.e. the emberbed 232 and/or the assembly base 234, and into thegrate 222. Alternatively, the second fasteners 244 can have anothersuitable design. Still alternatively, the emberbed assembly 228 can beselectively coupled to the grate 222 in another suitable manner.

It should be understood that the use of the terms “first fasteners” and“second fasteners” is merely for convenience and ease of discussion; andeither fasteners 242, 244 can be referred to as the “first fasteners”and/or the “second fasteners”.

As noted above, the emberbed 232 and the assembly base 234 can be formedtogether as a unitary structure. With such design, as shown in FIG. 2C(also shown in FIG. 2B), the assembly base 234 can provide a flatsurface (i.e. a “flat floor”) that extends laterally away, i.e.outwardly to the left and the right, from the emberbed 232.Alternatively, the emberbed 232 and the assembly base 234 can be formedseparately from one another, and can be selectively coupled to oneanother in any suitable manner.

Importantly, as provided herein, the emberbed assembly 228, e.g., theemberbed 232, is formed separately from the grate 222, and is thenselectively coupled to the grate 222. With such design, the emberbedassembly 228, e.g., the emberbed 232, can have a much smaller and lowerprofile than in existing electric fireplaces. This enables the presenceof the bed gap 230 (illustrated, for example, in FIG. 2A), and, thus,the ability to create a more realistic appearance for the electricfireplace 210, i.e. more like a traditional wood-burning fireplace.

It is understood that although a number of different embodiments of theemberbed assembly 28 for the electric fireplace 10 have been illustratedand described herein, one or more features of any one embodiment can becombined with one or more features of one or more of the otherembodiments, provided that such combination satisfies the intent of thepresent invention.

While a number of exemplary aspects and embodiments of an emberbedassembly 28 for an electric fireplace 10 have been discussed above,those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced are interpreted to include all such modifications,permutations, additions and sub-combinations as are within their truespirit and scope.

What is claimed is:
 1. An electric fireplace comprising: a grate havinga substantially horizontally-oriented middle section; and an emberbedthat is positioned substantially directly below the middle section ofthe grate, the emberbed being positioned spaced apart from the grate bya bed gap.
 2. The electric fireplace of claim 1 wherein the bed gap isbetween approximately one-half inch and four inches.
 3. The electricfireplace of claim 3 wherein the emberbed is selectively coupled to thegrate.
 4. The electric fireplace of claim 1 further comprising anassembly base that is formed together with the emberbed as a unitarystructure.
 5. The electric fireplace of claim 4 wherein the emberbed andthe assembly base are selectively coupled to the grate.
 6. The electricfireplace of claim 4 wherein the assembly base provides a flat surfacethat extends laterally away from the emberbed.
 7. The electric fireplaceof claim 1 further comprising an assembly light source that ispositioned directly underneath the emberbed, the assembly light sourcebeing selectively activated to create a glowing effect for the emberbed.8. The electric fireplace of claim 7 wherein the assembly light sourceincludes a plurality of LED light bulbs.
 9. The electric fireplace ofclaim 1 wherein the emberbed is formed from at least one ofvacuum-molded plastic, pour-molded resin, injected plastic or paperpulp.
 10. The electric fireplace of claim 1 wherein the emberbed isformed from vacuum-molded plastic.
 11. The electric fireplace of claim 1wherein the grate is formed from metallic materials.
 12. The electricfireplace of claim 1 further comprising at least one simulated log thatis positioned on top of the grate.
 13. The electric fireplace of claim12 wherein the at least one simulated log is formed from a molded resinmaterial.
 14. The electric fireplace of claim 1 further comprising afireplace housing, wherein the grate and the emberbed are positionedsubstantially within the fireplace housing.
 15. An electric fireplacecomprising: a grate; and an emberbed assembly that is selectivelycoupled to the grate.
 16. The electric fireplace of claim 15 wherein theemberbed assembly includes an emberbed and an assembly base that areformed together as a unitary structure.
 17. The electric fireplace ofclaim 15 wherein the grate includes a substantiallyhorizontally-oriented middle section, and wherein the emberbed assemblyincludes an emberbed that is positioned substantially directly below themiddle section of the grate.
 18. The electric fireplace of claim 17wherein the emberbed is spaced apart a bed gap from the middle sectionof the grate.
 19. The electric fireplace of claim 18 herein the bed gapis between approximately one-half inch and four inches.
 20. The electricfireplace of claim 17 further comprising an assembly light source thatis positioned directly underneath the emberbed, the assembly lightsource being selectively activated to create a glowing effect for theemberbed.
 21. The electric fireplace of claim 20 wherein the assemblylight source includes a plurality of LED light bulbs.
 22. The electricfireplace of claim 15 wherein the grate is formed from metallicmaterials, and wherein the emberbed assembly is formed fromvacuum-molded plastic.
 23. The electric fireplace of claim 15 furthercomprising at least one simulated log that is positioned on top of thegrate.
 24. The electric fireplace of claim 23 wherein the at least onesimulated log is formed from a molded resin material.
 25. The electricfireplace of claim 15 further comprising a fireplace housing, whereinthe grate and the emberbed assembly are positioned substantially withinthe fireplace housing.